When the right drill bit is in the right ground operated under the right conditions, more core ends up in the box at the end of a shift. There isn’t a perfect drill bit matrix or geometry that cuts every ground as quickly as possible. A Longyear bit may cut 17 inches per minute in Arizona, but cut just three inches per minute in Ontario.

Although diamond drill bit selection is often an afterthought, it’s just as important as drillers deciding how much water/mud to run or how fast to spin rods.

There are many factors to consider when selecting a drill bit, including the main objective of a project. As mentioned, the overarching objective is always more core in the box, but there are additional elements that need to be considered. For example, a rod trip takes significantly less time at 400 feet than a rod trip at 4,000 feet. While bit life is important, it’s less crucial at the top of a hole because that usually means sacrificing penetration rates.

In Australia, a site used two different bits at different depths. A Longyear Red Express bit was used to cut 60 centimeters per meter with a life of only 120 meters at the top of the hole. Once that bit was done they switched to a Longyear Yellow Stage 3, because rod tripping took too long. With this bit they only cut at 35 centimeters per minute but achieved a life of 300 meters per bit. Using a singular Longyear bit, this site put 6% more core in the box than they did with a competitor’s bit. However, using these two Longyear bits in tandem, they saw a 23% increase of core in the box over the competitor’s product. Sometimes, it’s more beneficial to cut faster even if it means tripping more.

Once a driller decides whether the objective is cutting faster or tripping less often, next it’s important to establish how hard the ground is to cut. Contrary to popular belief, the ground drillers cut is (probably) not the hardest ground on earth. This is where the Mohs scale comes into play. The Mohs scale is an exponential scale from 1 to 10 to quantify mineral hardness. Minerals with a higher Mohs hardness will scratch anything with a lower Mohs hardness. For example, a mineral classified as a four will scratch a three but not a five.

All the bits offered on the market today are targeting a specific range of the Mohs scale for the best performance. To determine the Mohs hardness of the rock to be drilled, a Mohs hardness scratch test kit is needed. This kit is a series of picks made of different materials that, when used properly, can determine the Mohs hardness plus or minus 0.5.

The Boart Longyear scratch test kit has four scratchers with eight replaceable tips and a sharpening stone. If the numbered tip scratches the rock, the rock is softer than the number on the tip. If a seven scratches and a six doesn’t, you know you’re in 6.5 rock. You would then select the bit created for that rock.

Once ground hardness is identified, Boart Longyear offers a Longyear Diamond Bits Hardness Rating & Comparison Chart to find a recommended bit for that ground. For example, Purple is meant for 1 - 4.5 rock, up to Red which is best for 7.5 – 9. Purple covers such a large range numerically because the Mohs scale is exponential (1 and 4.5 on the Mohs scale are closer together on “true” hardness than 7.5 and 9).

In the cross reference above, bit range overlaps, and the bars representing each drill bit are quite long. This is where the objectives of the site come into play. For example, if you are in a 6.5 rock, select a Green Bit or a Yellow Bit. Which one should you try first? It depends. If the site is cutting a lot of short holes and bit life isn’t a big concern, you would likely have the best luck with Yellow – it would penetrate faster than Green, but not have as long of life in 6.5 rock. On the flip side, if bit life is a concern because you’re drilling deep holes, you may prefer Green.

Another thing to consider for bit selection is geometry. While the Green bit is, in general, tougher than the Yellow, a Green bit with more open area and a Yellow with less open area will exhibit very similar cutting characteristics.

The geometries offered by Boart Longyear are all designed to cut a little differently. Within each color bar, the Express has the ability to cut harder rock than the Stage and the Stage will cut harder rock than the Tapered Waterway. This is a result of what is called, “open area”.

Open area is determined by finding the surface area of a disc with the same outside diameter and inside diameter as the drill bit, and subtracting the surface area of the drill bit with all the waterways cut in. What’s left is the area of the waterways, flutes, and rounds, and the percentage of this number compared to the area of the total disc is the open area. Express has an open area of 30%, Tapered Waterway has an open area of 25% and Stage has an open area of 20%.

Standard Waterways

• Most common waterway style
• Longest life based on lowest open area 15%

Tapered Waterways

• Pushes cuttings to the OD and reduces pressure across bit face
• Open area 25%
• Preferred

Express Waterways

• Faster penetration and/or lower weight
• Open area 30%
• Free-cutting formulas

Stage/GT

• Wide waterways, more versatile
• Better flushing and penetration than standard waterways
• Open area 20% for Stage

Deep ID Waterways

• Recommended for lost circulation applications; prevents the lifter case pulling into the bit and shutting off water
• Can be used instead of face discharge in triple-tube and piloted core lifter case
• Face Discharge preferred for core recovery. Open area based on waterway

Face Discharge Waterways

• Reduces water pressure on the core and redirects fluid to the face of the bit (reduces washing core material), aiding in core recovery
• Required for piloted core lifter cases
• Open area based on waterway

If cutting at the top range of these bars, more open area will be needed, and the Express, for the middle and bottom ranges, will use Tapered Waterway or Stage, respectively.

The Longyear Yellow and the Longyear Green bits overlap substantially in the cross reference. This shows either the Longyear Yellow or the Longyear Green can cut Mohs 7 rock. To cut this Mohs 7 quickly, a Yellow Tapered Waterway bit will be needed. To cut it more slowly and optimize bit life, a Green Stage bit should be used. A Green Express, a Green Tapered Waterway and a Yellow Stage would land somewhere in-between.

Once a bit has been selected for the rock type, crown height, and geometry, the last step is to collect data and test the chosen bit’s performance.

Once the ideal bit has been identified – it needs to be tested, and the only way to make an informed decision during testing is to collect data.

Here are three mandatory data points to collect:

• Penetration rate on every run
• Mohs hardness every run
• Bit life of every bit

Once the data has been collected, this information can be used to either validate the choice initially made or adapt based on unaccounted circumstances. For example, if the Green Stage bit was selected but the penetration rate wasn’t as high as expected, then the Green Express and the Yellow Stage would be good bits to try next. The Yellow Stage may not provide the desired life, but the Green Express may be a perfect in-between. All this shows in the data and at the end of the day more core ends up in the box.

With a combination of knowledge, the right tools, and good planning, every shift can be optimized, and subsequently, put as much core in the box as possible.

Learn more about bit optimization and the productivity results from the field - New Longyear Bits Put 23% More Core in the Box

Ready to start testing? Contact your local Boart Longyear representative or visit My Drill Store.

Using patented technology, the new Longyear bits have diamonds that are chemically bonded to the matrix creating a more versatile, faster penetrating, and a longer-lived bit. The new Longyear bits retain the smooth drilling characteristics drillers prefer, resulting in more core in the box on every shift for every crew. Available in 16mm more open, express geometry for even higher cutting speeds as well as 16mm Stage and 25mm Stage 3 configurations.

“Just some feedback… the other night I witnessed a bit cutting 24 inches a min … by far the fastest cutting bit Boart Longyear has made…” Boart Longyear Site Supervisor, Western Territory.

On the surface, the Laverton district is a flat, hot, dry environment with scattered acacia trees only interrupted by dry, salt lake beds, and gypsum sand dunes. The high concentration of salt results in a very saline aquifer. While the high salinity is hard on equipment it does not factor heavily into bit selection and drilling performance.

Underground, the formation is a mesothermal, meaning deep extending, gold deposit typical in Western Australia, composed of greenstone, a rock type common to gold deposits globally, basalts, magnetite shales and banded iron formations (BIF). 

Within this host rock, the gold is typically contained within intrusive dykes of quartz porphyry near the shear and fracture networks which supported gold-bearing hydrothermal flow. The greenstone, shale and even basalts are only of medium hardness and have the potential to be cut quite quickly, while the sections of BIF, quartz and fracture zones force slower penetration rates. The ideal bit would be versatile; free-cutting enough to easily handle the occasional BIF and quartz but tough enough to penetrate the greenstones quickly.

The underground portion of the mine is decline accessed and extends 900m below the original open pit. Due to its “nuggety” deposit, diamond drilling tends to underestimate grade, so the mine has adopted new techniques of grade control. RC drilling has been introduced underground to produce larger sample volumes, which match well with the bulk mining techniques being used. Considering that RC drilling is typically half the cost-per-meter and three times faster, and the industry-wide initiatives to drive down all in sustaining costs, a lot of scrutiny is paid to the productivity of remaining diamond drilling.

After optimizing drilling parameters, the incumbent product’s (Hayden 9AA and KS5) average performance, maxed out at 180 meters/bit life and 22 centimeters/min of penetration rate over the three months of monitoring. While solid performance, a new solution was needed to continue improving productivity.

The first step was to introduce the new Longyear Green Bit in a Stage 3 25mm configuration. The Longyear Green formula (Prototype P520) was selected to drill like the competitor’s 9AA formula with Stage configuration to maximize life. Comparing performance in the three-month period after adoption, penetration rate increased to 26 centimeters/minute and bit life nearly doubled, increasing to 356 meters/bit. The ease of use and consistency across shifts was appreciated by the crews and helped produce the measurable gain. These improvements combined to noticeably increase core in the box by 6%. The Boart Longyear drill crews correctly observed that such long life was not driving a significant increase in productivity as reduced tripping time has less impact than improved penetration, so the decision was made to trial even more free-cutting formulas.

The next bit trialed was the Longyear Yellow (Prototype P575) again in the Stage 3 25mm configuration to line up against the competitor’s KS5 and even 12-14. The penetration rate jumped to an average of 35 centimeters per minute and life held at an impressive 300 meters per bit. Since the bits were still achieving much better life, Boart Longyear Drilling Services moved one more step up to the Longyear Red bit (Prototype P566). Since the goal was to maximize penetration rate, the Longyear Red bits were produced in the 16mm express configuration with a more open area for enhanced penetration.

The Longyear Red bits achieved an astonishing 60 centimeters per meter penetration rate and still lasted 120 meters. With the goal of maximizing productivity, the drill crews decided to use one Longyear Red at the top of the hole and finish it with a Longyear Yellow in 25mm Stage 3. The results speak for themselves. After 3 months of measurement, this two-bit strategy averaged 283 meters/bit, still a 60% improvement over the competition and 34 centimeters per minute, a full doubling of penetration rate. The combined result put 23% more core in the box.

Express Geometry

With the competitiveness of today’s market, everyone is looking to cut faster, especially underground. To support higher penetration rates, we have combined the new Longyear formulas with a new, more open express geometry. Tapered intermediate waterways improving flushing and prevent accumulation of debris. Designed for fast cutting in competent ground, the new express geometry is available in our 16mm crown heights to maintain bit life at higher cutting speeds.

After the promising initial results, trials were started using the new Longyear bits on all Boart Longyear Drilling Services sites in Australia and select sites globally. Now, all sites in Australia have converted to great effect on productivity. Over the next six months, the new Longyear bits in the Longyear line will be launched, moving from prototype to full production. Longyear bits are now stocked in Australia and available to order.